Your 24/7 time-efficient, one-stop facilities for parts, field repairs, field services, packing & seals!

Repairs Field Services EngineeringParts Field Machining ReverseParts Field Machining Reverse Repairs Field Services Engineering

ISO 9001 Certified

Alin Machining Co., Inc. d/b/a

Power Plant Services"The Turnkey Solution"

Turnkey Solutionfor Power Plant

Equipment

Power Plant Services (PPS) has been in operation since 1998. We currently have locations in Melrose Park, IL; Oswego, IL; Marion, OH; and Ball Ground, GA. PPS is truly a turnkey, aftermarket manufacturer and service provider.

We have increased our capabilities to meet customer’s needs by providing services such as Parts Manufacturing, Technical & Engineering Services, Repair Services, Field Machining, Field Service, and exceptional delivery time.

Who is Power Plant Services?

We perform emergency work as well as planned outages throughout the United States and Internationally including Aruba, Australia, Brazil, Canada, Dominican Republic, Germany, India, Indonesia, Italy, Israel, Jamaica, Kuwait, Malaysia, Mexico, Nicaragua, Philippines, Poland, Puerto Rico, Saudi Arabia, Singapore, South Africa, South Korea, Switzerland, Thailand, Turkey, United Arab Emirates, and the United Kingdom.

Our customer service department is available to assist customers 24/7.

PPS customer service associates are available to process quotes, coordinate, track, and resolve any issues that may arise. Furthermore, they will follow up to ensure you receive your quality product on time and do much more!

PPS has developed an online inventory system where our customers can go to request quotes or verify we

manufacture the parts they require. We have also included an online form for submitting quotes. Visit our website to discover these tools.

Should you require assistance in obtaining pricing, availability, or placing an order contact our customer service department by phone (708) 345-8600; fax (708) 345-9181; email sales@ppsvcs.com; or by website www.ppsvcs.com.

Customer Service

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Oswego, IL Ball Ground, GA Ball Ground, GA

PPRS - Repair Services & Field Machining 80 Kendall Point Dr., Oswego, IL 60543Ph: (708) 345-8600 Fax: (630) 820-8431

PPRS - Repair Services & Field Machining 345 Wilbanks Dr., Ball Ground, GA 30107 Ph: (708) 345-8600 Fax: (770) 345-8666

PPFS - Field Services508 Wilbanks Dr., Ball Ground, GA 30107Ph: (708) 345-8600 Fax: (708) 538-1829

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Industries We Serve

Our Facilities

Melrose Park, IL Melrose Park, IL Marion, OH

PPS - Special Parts / Headquarters 3131 W. Soffel Ave., Melrose Park, IL 60160Ph: (708) 345-8600 Fax: (708) 345-9181

PPS - Standard Parts Division 3201 W. Soffel Ave., Melrose Park, IL 60160Ph: (708) 681-1050 Fax: (708) 681-0143

PPS - Packing & Seals Division 875 W. Mark Drive, Marion, OH 43302 Ph: (708) 345-8600 Fax: (740) 223-1750

Power Generation Pulp & Paper Refineries

Steel Petro Chemical

Capabilities PPS has a number of strengths when it comes to assisting our customers including:

Emergency service – 24 hours, 7 days per weekState-of-the-art manufacturing facility for turbine and other componentsRotational equipment repairValve inspection / repair / restorationReverse engineering expertiseProject management servicesISO 9001/2008 CertifiedMinority CertifiedISNetworld Member ContractorIntegrated solution of parts, repairs, field machining, & field services24/7 Trucking Services

PPS has provided quality after-market parts for over a decade. Our current manufacturing division, over 100,000 sq. ft., is dedicated to making custom and standard parts.

To guarantee a quick turn-around on your parts request, PPS commonly stocks items such as 422SS, Incoloy, Alloy Steel, and other strategic materials.

Our wide range of equipment for our manufacturing division includes:

Mazak Power Master Lathe (36" x 100")

4 - Axis CNC Lathes (mill & turn) Live tooling 4 - Axis Wire EDM 5 - Axis CNC Integrex 5 - Axis CNC Mill Water Jet Cutting (6 ft. x 12 ft., up to 6" thick)

Gun Drill (2" drilling diameter x 60" L)

Twin Spindle Gun Drill (1" drilling diameter x 36" L)

Sandblasting (30'L x 20'B x 12'H)

Automatic Welding (TIG / MIG / Plasma / Sub-Arc)

Stellite ID / OD Welding (1.5" ID x 30" L)

Surface Grinding OD / ID Grinding Honing Mazak M5 [Qty. 3 (24" x 120")]

4 - Axis CNC Milling (vertical & horizontal 2 pallet)

Cincinnati Vertical Boring Mill (90" OD Table, 100" maximum swing, 100" under rail, 57" head travel)

Shirubra Manual Horizontal Mill (32" spindle travel, 70" vertical travel, 155" horizontal travel, table size, 59" square extended size 59" x 118")

Nitriding / Malcomizing (DIA 24" x 70"L)

Additional machine capacity of 150 CNC machinery (over 150,000 sq. ft. shop force)

Manufacturing

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Valve Parts

We employ over 75 machinists to ensure we have the necessary capacity available to ensure the fastest turnaround possible.

• Stems• Bushings• Strainers• Bypass Discs (stellited)• Trim Parts• Cross Heads• Keys• Seats • Balance Chambers• Complete Valve Assembly• BFPT Valve Assembly

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Fasteners

• Studs• Nuts• Bolts• Pins • Washers

Typical fastener items provided to the utility and industrial market for years. In emergencies, these items can be provided in days.

Seals and Packing

PPS specializes in manufacturing (Marion, OH Division)

• J & L Seals• Flat Seals• Seal Rings• Pressure Seal Ring• Installation Service available by PPRS

We offer complete packing box and oil deflector assembly as well.

Erosion Shields

PPS manufactures standard and custom erosion shields. We offer various grades of materials in varying thickness. We stock all brazing supplies such as fluxes, silver solder ribbon, LP Blade Tie Wire, Lashing Lug Materials, “Finger” Lock Pins and Reamers.

Reamers

All types of piloted reamers and dovetail pins available from stock for quick delivery.

Blade / Diaphragm Manufacturing

PPS has a state-of-the-art blade manufacturing facility. We manufacture blades of all makes and models for Steam & Gas Turbines from initial CAD / CAM / solid works design to our CNC machining.

Blades• Air Foils up to 30"• Integral Shrouds• Angled Tips• Finger, Ball, Internal & External, Dovetail, T & Double T Roots• Forge Blades• Tie Wire Holes• Straight or Twisted• Mid Spans• Tenon (Multi Tenons)• Axial Entry• Tangential• Installation hardware

Diaphragms• Nozzles• Diaphragms• Coupons

Raw Materials

PPS stocks a large amount of raw materials in our warehouse in order to expedite the process of manufacturing parts. Our raw materials inventory includes:

• 422 / 403 / 403 CB / C410 • Nitralloy • B16 • Incoloy 718 / 750 / 901 • 1-¼ Chrome-moly-vanadium bars and forgings• H46• Inconel• 300 SS Series• Stellite• Refractalloy• Nimonic AD• Nico-Silver, Ni-Resist

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Gas Turbine Replacement Parts

Our team of engineers work from sample parts, prints, or specifications. • Full range of fasteners including compressors thru bolts• Bearings• Oil Deflectors• Keys, Pins, & Rings• Compressor Rotor Blades & Discs• Stator Blades

Hydro Turbine Replacement Parts Including, but not limited to:

• Lantern Rings• Shaft Rings• Seal Rings• Thrust Plates• Packing Glands• Wicket Gate Studs

• Bearings• Bearing Houses• Stuffing Box• Stuffing Box Covers• All Standard Fasteners• Bearing Shoes

Our repair division, PPRS, enables us to complete repairs and field machining in our shop or on-site at your facility. PPRS works in conjunction with PPS to manufacture standard and customized parts efficiently and quickly to decrease your downtime during outages.

PPRS performs repairs of valves, diaphragms, rotors, deflectors, turning gears, pumps, shells, nozzles, strainers, gear boxes and much more!

PPRS has all the necessary tools and equipment to disassemble, repair, and reassemble any mechanical equipment. These repairs can be performed in our shop or on-site at the power plant. We have facilities in Oswego, IL and Ball Ground, GA to serve your repair and field machining needs.

Our continuously expanding equipment business resources that includes but is not limited to:

• Pump Division• 20 Ton O / H Crane, height clearance 23' • 13 assembly and disassembly work areas with individual jib cranes• Sandblasting Capabilities (22'W x 13'H x 40'L)• Manual and Semi-Automatic Welding Stations (SMAW, GMAW, GTAW, STAW, SAW)• Tools / Parts Crib, Standard Fasteners, Valve Parts, Turbine Outage Items• Stress Relieving• Stock Inventory 422 SS, Incoloy, Alloy Steel, Other Strategic Materials• Portable Lathe & Balance Machinery for on-site projects• Seals & Packing Installation

▲Poreba Lathe

▲Bullard VTL▲Omba VTL ▲Niles Boring Mill

ISO 9001 CertifiedPower Plant Repair Services, LLC

"The Turnkey Solution"

Our vast array of capabilities helps us to assist our customers in the most efficient manner. From scheduled maintenance outages to emergency rush services, the PPS team possesses extensive

experience working with all brands of turbomachinery rotors and all OEM steam turbine diaphragms and nozzles and can provide fabrication and welding services for structural components.

▲Portable Lathe

Pump Division• Pump Disassembly• Pump Cleaned and Inspected• Complete Assessment• Repairs in Our Shop or On-site• Will Manufacture New Components

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Rotating Equipment

Stationary Equipment

Welding Services

• Minor diaphragm repair in-shop & on-site• Major Diaphragm & Nozzle Repair in-shop• Complete Computerized area check, as requested

• Manufacturing of Nozzles & Diaphragms• Other Diaphragm Hardware Manufacturing• Blast Cleaning Facility (22'W x 44'L x 13'H)• VBM capacity, up to 196"

• Shielded Metal Arc (SMAW)• Gas Metal Arc (GMAW)• Gas Tungsten Arc (GTAW)

• Plasma Transfer Arc (PTA)• Submerged Arc (SAW)

• Blade removal, manufacturing, & installation• Blade Restoration• Other Blade Hardware manufacturing & installation• Blade Cleaning Facility (22'W x 40'L x 13'H)

• Journal Bearings Restoration• Thrust Collar• Cover stock Manufacture• Lathe capacity up to 60" swing & 24' between centers• Up to 30 Ton Overhead Crane capacity

Valve Assembly Repair

PPRS is capable of doing on-site as well as in-shop repairs of your valves. We have proper fixtures, tooling, manpower, and equipment to repair most common valves of different OEM’s.

• Our valve assembly repair department follows proper inspection procedures.

• Incoming inspections and final inspection data are documented and submitted to the customer in a timely manner.

• Highly skilled machinists work a 24/7 schedule, operating CNC and manual machine tools.

• Project engineers and project managers are devoted to the customer and are responsible for in-process coordination.

• Our in-house parts manufacturing and repair capabilities gives you fast and reliable operation.

PPRS inspects and repairs turbine valves, which include: Control, Throttle, Intercept, Main Stop, Reheat / Combine Reheat, Governor, Blow Down, and Ventilator.

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Steam Turbine Rotor & Carrier Overhaul

Components were flown to our Repair facility for emergency inspection and repairs, during further inspection it was found that the lock slots on all the rotating blades were damaged, by a third party, during an attempt to remove the blades on site.

Blades were reverse engineered in house, manufactured and installed. Additionally, due to damage to the notch lock areas of the rotor, an

innovative device was incorporated into the rotor (mechanical inserts) as a repair without welding.

All 276 rotating seal and 208 stationary seals were removed and new seal installed. Also a weld restoration to the No.2 journal was performed.

The work was completed ahead of schedule.

▲Rotor Blades Damage

▲QC of Carrier After Machining ▲ Rotor After Repairs

▲ Reverse Engineering

▲ Journal After Welding

Gas Turbine Rotor

Thrust bearing failure caused extensive thrust disc damage and rubbing to the compressor vanes and turbine blades. Workscope included the removal of existing integral thrust disc, weld restoration to restore

thrust disc, final machining and grinding to thrust disc, replacement of 1st stage turbine blades, grinding dressing and blending of compressor vanes, polishing of journals, and low speed balance.

▲Rotor after repairs completed▲Rotor during welding

▲Finished Thrust Disc

▲Damaged Thrust Disc

▲Compressor Vane damage

▲Preheating before welding

▲Compressor Vane after dressing

▲Submerged arc welding

▲Stress Relieving Two Turbine Rotors After Weld Restoration

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Valve Racks

The three valve racks below were received for disassembly and complete inspection. PPRS identified a number of necessary repairs including

the removal of all bushing bores and reestablished peening lips, manufacturing of stems and discs, and complete assembly.

▲Reassembled Valves-Steam Chest with Valve Mounted

▲Disassembled parts ready for cleaning and NDE ▲Valve Rack repaired, packed for shipping

▲Components after NDE inspection

Control Valve Repair Control valve received for complete disassembly, cleaning and inspection, repair of components, and final assembly.

▲ Repairs on Main Stop Valves and Control Valve Components

▲ Repaired CV Stem

▼Control Valve Bonnet prepped for shipping

Discs before and after repair ►

Blue Check on Stem ►

Gear Box

Customer sent in HP and LP turning gears with history of operational problems. Workscope included complete

disassembly, cleaning and inspection, manufacturing of new gears and bearings, and complete reassembly.

Nozzle Manufacturing

Nozzle plate had severe sidewall cracking – workscope included reverse engineering and design upgrade to nozzle plate. Created manufacturing drawings,

manufactured component parts, fabricated and welded nozzle plate, finished machine, NDE, and final dimensional inspection.

▲Assembled parts ready for welding▲Assembled nozzle during welding

▲Received Gear Box ▲ Disassembled Gear Box Parts ▲Reassembled Gear Box Parts

▲Damaged Gear ▲Repaired Gear ▲Cleaned, Repaired & Reassembled Gear Box

Parts ready for assembly ►

►Finished machining nozzle

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Inner Shell & Nozzle Received Nozzle Box, Inner Shell, and Diaphragms that ran in over temperature conditions and fatigued the materials to the point of failure – the nozzle block and inner shell locating rings severed and failed, allowing the nozzle block to move axially ¾". The 2nd, 3rd, and 4th stage Diaphragms also failed.

Workscope included the design calculations for repair of the locating rings, the reverse engineering and manufacturing of three diaphragms and nozzle ring, final machining, and final assembly of the repaired components prior to shipping.

▲Received Inner Shell

▲ Diaphragm in manufacturing process

▲Repair Inner Shell with Diaphragms installed

▲ Received Nozzle Before

▲ Finished machined Diaphragm▲Received Diaphragm

▲Nozzle during weld repair

▲Finished Nozzle Block assembled to finish Inner Shell

Field Machining PPRS has the capability to complete repairs on-site when parts cannot be transported. Our team includes experienced machinists that will work carefully on your power equipment to decrease the amount of downtime you may experience. Power Plant Repair Services stands ready to provide the tooling for your Turbine / Generator outage needs. We currently have four (4) major tool sets, (2) minor tool sets (set up for valve outages, etc.), (2) metric sets, as well as warehoused spare tooling. The tool sets have all tooling safe and securely stored within 20’ shipping containers. We continually review, inspect, and purchase the equipment as required to complete inspections and repairs on your machines as efficiently as possible. All tooling sets have at a minimum duplicates to assure no tooling delay issues.

PPRS Field Equipment includes: • Portable Machine Shop

• 20’ Container• Surface Grinder• Engine Lathe• Milling Machine• Drill Press• Punch Press

• Portable Lathe• Portable Balance Machine• Portable Welding Equipment

Field Services Power Plant Field Services (PPFS) is a growing division of Power Plant Services (PPS). We are diligently working to expand and offer quality services to our customers.

This division allows us to be an integrated provider of parts and services for the power generation industry.

Our team of professionals have extensive experience in managing both large and small field services projects across the United States. We are very excited to announce that we can provide you quotes on any and all of your Field Service requirements. The PPS goals of providing you with exceptional customer service, quick turnaround, and quality parts remains intact.

PPFS is continually increasing the equipment needed to complete inspections and repairs on your machines including multiple tool trailers.

During the 2015 outage season, PPFS successfully completed 14 projects throughout the year.

Valve and Components Banded for Shipping

Power Plant Field Services

Work performed by skilled craftsmen in a neat, safe, FME conscious environment.

• Major Inspections or Overhauls• Minor Inspections• Combustion Inspections• Hot Gas Path Inspections• Bore Scope Inspections• Boiler Feed Water Pump• Boiler Feed Pump Turbine

• Welding & Metal Fabrication• Generators• Turbine Retrofits• Auxiliary Equipment• Valves• Alignments• Seals and Packing

On-Site Valve Inspection On-Site Turbine Repair

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PPS & PPRS also utilize our own trucking service. PPS Trucking, LLC was created to bridge the gap, to serve customers with a fully insured, newer fleet, and reliable transportation services to transport highly valued and time-sensitive shipments. PPS Trucking, LLC is at our Melrose Park facility. We have multiple vehicles in our fleet to deliver or pick up your parts whether you are a short distance from our offices or across the country.

PPS ShiPPing Fleet

▲PPS 12ft Flat Bed Truck Payload 4000 lbs.

▲PPS Pickup Truck Payload 2000 lbs.

▲PPS Semi Truck Payload 47,500 lbs.

▲PPS Transit Van Payload 1000 lbs.

▲PPS 14ft Box Truck Payload 4000 lbs.

▲PPS Sprinter Van Payload 3000 lbs.

▲PPS 30ft Flat Bed Truck Payload 10,000 lbs.

• Coordinate Measuring Machines• Optical Comparator• Portable FARO Arm• Niton Material Analyzer• NVision Laser• Material Certified through Traceable Documentation

• Understanding of Metallurgical Properties• Product Application Knowledge• CAD/CAM Systems using Solidworks, AutoCAD, and MasterCAM

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Engineering & Reverse Engineering Our full-time Engineering department has over 6 decades of direct power-related experience covering a large range of manufacturers as well as extensive experience and management in Reverse Engineering. We can rapidly replicate your part(s) to the same precise dimensions per industry standards.

Our Engineering Department’s strengths rely in product application knowledge, understanding of metallurgical properties, and material certified through traceable documentation.

Reverse Engineering services provide a valuable alternative aftermarket source for just about any part. Reverse Engineering customers get fast delivery, competitive prices, and precision parts. Reverse Engineering can be performed at our shop or in the field.

State-of-the-Art Reverse Engineering using precision measuring devices, including:

The cutting edge technology we utilize in our facility includes state-of-the-art dimensional evaluation using flexible, highly accurate technology including CAD / CAM.

Coordinate measuring machine (CMM) 3-D laser scanning and Material analysis equipment (NITON).

Rerates We work with our Engineers and consulting engineering firms to provide you rerates and other engineering studies on any turbine up to 200MW.

We have successfully completed 5 projects by the end of 2015.

Customer Testimonials*

“Thank you for your conscientious efforts this year during our planned and unplanned outages ... the quality of work performed by PPS on both planned and emergent basis was outstanding ... PPS has always stepped up to the plate for us day or night, and knocked time off ... critical path during the steam turbine outage with the Stage I and II diaphragm repair ... The work received is always done to the best of standards. Every minute counts when marketed units are being held out in forced outage, and it is nice to know that the parts received are going to be made to exact specifications.”

“I just wanted to drop you a quick note regarding the recent work PPS performed ... I wish to express my gratitude for the hard work your team brought forth during this job and, in particular, the clear, amicable communication I received ... concerning engineering anomalies and deliverable throughout the design and manufacturing process. It is a pleasure to have direct, honest engineering support and all interactive members of your organization grasped that basic concept.”

“You know the biggest reason in my opinion that PPS does so well is that you guys are willing to do what it takes to help your customers out! You do what you say you’re going to do and you do it as quickly as possible too. I appreciate everything that you have and continue to do for me during outages! Thank you very much for the support!”

“...Turned around a part that would have taken the station 12 weeks to receive ... a 1-2 week process ... absolutely amazed.”

“I am very impressed with you guys looking forward to do(ing) more business with you in the near future.”

“... Functioning better than they have seen in the last 25 years!”

“Just to say thanks for the quick job on the ... sealing rings. They were spot on and fit very well. Please pass this along to the machinists and all who had a part in these.”

“The strainers we purchased from you ... have been installed (ahead of schedule due to early shipping on your part) with no issues of any type, I just wanted to take a few minutes to say “THANK YOU” to all involved with this project. Even at first when we weren’t exactly sure what we wanted. Everyone all the way thru to delivery were helpful and pleasant to deal with.”

... fantastic! ...

...great work...

... exceptional round of support ...

...impeccable...

...amazed ...

* Direct quotes from customers regarding Alin Machining, Power Plant Services & Power Plant Repair Services support, quality of work, and quick turnaround.

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ionsTurnkey Valve Repair Services

PPS is the provider of Turnkey Valve Repairs.

Turnkey Solutions for Combined Cycle UnitsPPS has worked on various combine cycle units, involving OEM and Multi OEM arrangements. Our work experience includes Alo, D11, and other units. PPS can provide consumable Kits for gas turbine as well as steam turbine.

Field Services

Repair Services

Field Machining

Technical Director

Steam and Gas Turbine KitsParts

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Remove Valves at Job Site

Inspect & Provide Report at Shop or Job Site

Repair Services

Provide Parts

Provide Field Machining

Reinstall Valves at Job Site

© 2016 All rights reserved. All photos and drawings are property of Alin Machining Co., Inc., Power Plant Services, Power Plant Repair Services, and Power Plant Field Services and should not be copied or reused without written permission.

MKL-002, Rev-2, 0116